Tool wear and tool life performance of TiA1N coated carbide cutting tools when turning XW 42 hardened tool steel

Abstract

Hard turning is an alternative technique that can be used for finishing operations of hardened material (HRC 45 and above). CBN and ceramic tools are widely used for finish hard turning (54-55 HRC), but these tools are associated with significantly higher cost. This study was undertaken to investigate the performance of KC 5010 FP when turning XW 42 hardened tool steel (54-55 HRC). Tool performance, tool failure modes and wear mechanisms were investigated under various cutting conditions (V=100, 123, and 150 m/min, f=0.08, 0.1, and 0.125 mm/rev). Tool failure modes were also investigated, and flank wear, crater wear, and catastrophic failure are found to be occurring on the tool while flank wear is the main wear form found on tool. The wear mechanisms responsible for the wear formation are abrasion and adhesion. Mathematical models for tool life and surface roughness were developed using experimental design technique. Tool life and surface roughness models can be used for coated carbide tool KC 5010 FP for finishing hardened tool steel XW 42 (HRC 54-55) under cutting the condition investigated.